Multi-colored yarn and textile formed therefrom

ABSTRACT

A space-dyed yarn and textile construction formed therefrom is provided. The space-dyed yarn includes a multiplicity of discrete color segments arranged along the length of the yarn. The color segments are of finite lengths which may be in the range of less than about 2 inches. The yarns may have linear densities under about 500 denier. A process and apparatus for production of the space-dyed yarns are also provided.

TECHNICAL FIELD

[0001] The present invention relates generally to multi-colored yarnsand to an improved textile structure of enhanced aesthetic characterutilizing multi-colored yarn constituents. More specifically, theinvention relates to space dyed yarns and to a textile material formedfrom a plurality of such yarns at least a portion of which are lowdenier yarns including short space-dyed color segments along theirlength. Portions of the color segments are disposed in a discontinuousarrangement at discrete visible locations across an outer face of thetextile material without the occurrence of chevrons or other potentiallyundesirable patterning affects. A method and apparatus for applying theshort color segments to the multi-colored yarn constituents are alsoprovided.

BACKGROUND OF THE INVENTION

[0002] It is well known to utilize colored yarns within textilematerials to impart desired aesthetic characteristics to the textilematerial. Color is generally imparted to yarns by use of bulk dyeingpractices in which a single color is applied to bundles of yarn immersedwithin a dye bath. Typical dyes as are known to those of skill in theart include disperse dyes, acid dyes and basic dyes. As will beappreciated, upon completion of such a bulk dyeing operation, the dyedyarn is typically of a substantially uniform solid color. Thus, in orderto provide a multi-colored appearance to a textile material formed fromsuch bulk dyed yarns, it may be necessary to utilize a number ofdifferent colored yarns. However, the utilization of such bulk dyedyarns nonetheless tends to establish visually distinguishable patternswithin the resulting textile material which maybe undesirable to someusers.

[0003] It is also known to utilize so-called “space-dyed” yarns withinpile-forming textile materials such as carpeting to provide a random orpseudo-random pattern within the material. One such carpeting materialis illustrated and described in U.S. Pat. No. 5,413,832 to Willey thecontents of which are incorporated by reference herein.

[0004] Several methods are known for space dyeing of yarns so as toimpart segments of various colors along the length of such yarns. Onesuch known method is the so-called “knit-deknit” method in which yarnsare knit into a construction across which bands of color are introduced.The knit construction is thereafter unraveled so as to yield the lengthsof yarn with substantially random coloration patterns disposed alongtheir length. While useful, the “knit-deknit” process may be difficultto control and may be unduly time consuming and complex to enableefficient and cost effective manufacture of large quantities ofmaterial.

[0005] In order to address the deficiencies of the “knit-deknit”process, several batch-type and continuous processes have beenadvocated. Among the batch-type processes (in which a predeterminedquantity of yarn is treated at one time), it is known to inject yarnpackages with a number of different colored dyes to yield a space-dyedproduct. However, such batch process may be relatively costly andrequire more product handling than is desired.

[0006] As an alternative to the batch-type processes, several types ofcontinuous space-dyeing processes (in which moving yarns areindividually or collectively treated) are also known. One suchcontinuous process is illustrated and described in U.S. Pat. No.5,594,968 to Haselwander et al. the teachings of which are incorporatedby reference herein. In this process yarns are intermittently pressedagainst dye applicator rolls to impart segments of dye to the yarns in apredetermined order. The yarn is held against the dye applicator rollsby a pattern roll supporting deflecting rods or paddles arranged inspaced relation at the surface of the pattern roll up stream of the dyeapplicator roll so as to provide a defined period of contact between theyarn and the dye applicator roll as the deflecting elements are pressedagainst the yarn at locations adjacent to the dye applicator rolls.Based upon claims made in available advertising literature, such asystem is believed to permit the application of a controlled pattern ofdifferent colors to yarn having a linear density of about 500 to about5000 denier and the length of the individual color segments achievablein such an apparatus is believed to be in the range of at least 0.5inches (12.7 mm) or more.

[0007] U.S. Pat. Nos. 5,491,858 and 5,557,953 to Massotte et al.(incorporated by reference) disclose equipment and procedures forapplying dye segments to yarns using spinning disk elements havingspaced openings which permit passage of dye droplets towards the yarnswhen the disk openings and yarns are in opposing relation to oneanother. Such arrangements have been promoted as providing short colorsegments, but are believed to be useful only with relatively large yarnshaving linear densities in the range of about 720 denier and greater. Aswill be appreciated, such high denier materials provide an enlargedimpact target area and are thus more likely to be contacted by asufficient number of the disperse dye droplets emerging from thespinning disks to effect coloration at a desired localized position.Conversely, such disperse droplets may tend to miss smaller diameteryarns.

[0008] Another continuous process is illustrated and disclosed in U.S.Pat. No. 6,019,799 to Brown et al. the teachings of which areincorporated by reference herein. The process disclosed therein utilizesa substantially direct application of a spray pattern of dye liquordroplets towards a yarn sheet. The dye stream is cycled on and off toapply a desired patterning effect. Such a process may be useful inapplying dye segments to low denier yarns but the color segments appliedare relatively long being in the range of about 2 inches (50.8 mm) orgreater.

[0009] In view of the above, the prior art has recognized a number oftechniques for forming space-dyed yarns. However in order to obtainrelatively short color segments of less than about 2 inches (50.8 mm),the yarns have been characterized by relatively high linear densityratings of 500 denier or greater. Moreover, in order to obtain colorsegments of less than 0.5 inches (12.7 mm), the yarns have been requiredto have even higher linear densities of at least about 720 denier orgreater.

SUMMARY OF THE INVENTION

[0010] The present invention provides advantages and alternatives overthe prior art by providing space-dyed yarns incorporating discrete colorsegments which may have lengths less than about 2 inches (50.8 mm) whilenonetheless being characterized by virtually any linear densityincluding linear densities substantially less than about 500 denier.Textile materials incorporating such space-dyed yarns as well asprocesses and equipment for manufacturing such space-dyed yarns are alsoprovided.

[0011] In accordance with one aspect of the present invention, amulti-colored yarn is provided including a plurality of discrete colorsegments arranged in predefined spaced relation along the length of theyarn. The yarn may have a linear density less than about 500 denier andat least a portion of the color segments may be of a controlled lengthless than about 2 inches (50.8 mm).

[0012] In accordance with another aspect of the present invention, atextile material is provided which includes a plurality of space-dyedyarns within a cohesive knit or woven construction. The space-dyed yarnsare of relatively low linear density in the range of about 500 denierper yarn or less and include a multiplicity of discrete color segmentsarranged along the length of the yarn. A portion of the color segmentsare of finite lengths in the range of less than about 2 inches (50.8mm). The short length of the color segments results in portions of thediscrete color segments forming disperse color spots at discrete visiblelocations across an outer face of the textile material. The relativelylow linear density of the yarns forming the textile material provides adesirable tactile character while permitting the textile material tohave a relatively low mass per unit area which is preferably in therange of about 8 to about 22 ounces per square yard (about 271 to about746 grams per square meter).

BRIEF DESCRIPTION OF THE DRAWINGS

[0013] The present invention will now be described by way of exampleonly, with reference to the accompanying drawings which constitute apart of the specification herein and in which;

[0014]FIG. 1 is a side view of a space dyeing range for applying andfixing short dye segments along a yarn;

[0015]FIG. 2 is a cutaway side view of a dye application unit within thespace dyeing range for applying dye segments to a yarn;

[0016]FIG. 3 is a view taken along line 3-3 in FIG. 2 illustrating anarrangement of dye application modules in opposing relation to a yarnsheet;

[0017]FIG. 4 is a partially cutaway view of a dye application moduleincorporating a multiplicity of color applying dye nozzles and gasnozzles for projection of interrupting gas jets;

[0018]FIG. 5 is a view similar to FIG. 4 upon activation of theinterrupting gas jets;

[0019]FIG. 6 illustrates an arrangement of color segments along a yarnas may be applied by the dye application unit illustrated in FIG. 2;

[0020]FIG. 7 illustrates a simplified woven construction incorporatingthe colored yarn arrangement of FIG. 6;

[0021]FIG. 8 is a needle bar diagram illustrating an exemplaryconstruction for forming a plush double needle bar knit fabric using lowdenier colored yarns; and

[0022]FIG. 9 is a needle bar diagram illustrating an exemplaryconstruction for forming a warp knit fabric using low denier coloredyarns.

[0023] While the invention is illustrated and will be described inconnection with certain potentially preferred embodiments, proceduresand practices, it is to be understood that in no event is the inventionto be limited to such illustrated and described embodiments, proceduresand practices. On the contrary, it is intended that the presentinvention shall extend to all alternatives and modifications as mayembrace the principles of this invention within the true spirit andscope thereof.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0024] Reference will now be made to the drawings, wherein to the extentpossible like reference numerals are utilized to designate likecomponents throughout the various views. FIG. 1 shows a space dyeingrange 10 for use in applying and fixing dye to a plurality of yarns 12.As illustrated, the range 10 preferably includes a creel 14 which holdsa multiplicity of yarn packages 16. Individual yarns 12 from eachpackage 16 are passed through a first comb 18 wherein the yarns 12 arearranged in a substantially uniformly spaced, parallel fashion so thatthe yarns 12 do not overlap and are properly spaced in side to siderelation to form a yarn sheet 20. The yarn sheet 20 passes through a dyeapplicator 22 for application of patterned color segments in apredefined arrangement along the yarns 12 in a manner to be describedfurther hereinafter. After dyeing, the yarn sheet 20 exits the dyeapplicator 22 and passes through a drying oven 24 as will be well knownto those of skill in the art. After exiting the drying oven 24 the yarnsheet 20 enters a yarn inspection system 26 to detect any breakage ofthe individual yarns 12. The yarns 12 are then wound by a winder 28 intopackages 30. The packages 30 of dyed yarn are later fixed by anappropriate method such as by autoclaving, then washed to remove anyexcess, unfixed dye and dispersing agent. The yarn is thereafter driedand transported to an apparatus such as a weaving or knitting machinefor formation into a cohesive textile construction.

[0025] Turning to FIG. 2, within the dye applicator 22 the yarn sheet 20passes through a second comb 32 and loops around an indexing roll 34. Anencoder 35 linked in communication with the indexing roll 34 monitorsthe progression of the yarn sheet 20 and communicates such data to anoperating computer 33 (FIG. 1) which has been programmed to control theapplication of a sequence of color segments at predefined locationsalong the yarns 12 within the yarn sheet 20 in a manner as will bedescribed further hereinafter.

[0026] As illustrated, upon exiting the indexing roll 34 the yarn sheet20 is passed over a dye application roll 40. The dye application roll 40may be rotated by a motor 36 via a drive belt 37. Of course, other driveassemblies as will be known to those of skill in the art may also beutilized. As shown, the dye application roll is mounted in rotatingrelation within a dye trough 42. The dye application roll 40 ispartially submerged within a reservoir of dye liquor 44 such that uponrotation of the dye application roll 40 by the motor 36, the dye liquor44 is spread across the contacting yarn sheet 20 so as to apply a firstuniform base shade along the length of the yarns 12 within the yarnsheet 20. As will be discussed further hereinafter, the base shade maybe used to establish colored segments along the length of the yarns 12.Of course, in the event that the desired base shade is white, then nodye liquor 44 need be applied to the yarn sheet 20. Upon exiting the dyeapplication roll 40 the yarn sheet 20 is passed through a third comb 46and towards a series of dye stream application stations 50 each of whichmay apply a different colored dye to the yarn sheet 20 in a successivepattern.

[0027] As illustrated in FIG. 3, the dye stream application stations 50are disposed substantially transverse to the travel path of the yarns 12forming the yarn sheet 20. As shown, each of the dye stream applicationstations 50 preferably includes a multiplicity of dye stream applicationmodules 52 to apply dye streams to a number of opposing yarns 12.According to the illustrated and potentially preferred practice, each ofthe dye stream application modules 52 is preferably substantiallyidentical in configuration and is linked to a common dye feed source 54such that each dye stream application module 52 applies the same coloracross the width of the yarn sheet 20. Of course, one or more modulesmay be fed by an alternative dye feed source if desired such thatdifferent colors are applied across the width of the yarn sheet 20.

[0028] Referring now simultaneously to FIGS. 4 and 5, one practice forthe application of dye segments along individual yarns 12 isillustrated. As shown, the dye stream application modules 52 eachinclude a multiplicity of dye nozzles 56 projecting in angled relationtowards the yarn sheet 20. The dye nozzles are arranged so as todischarge a narrow stable dye stream 58 to the side of the individualyarns 12 such that under normal conditions there is no interactionbetween the dye stream 58 and the yarns 12. According to the potentiallypreferred practice, each of the dye nozzles 56 has an outer diameter ofabout 0.065 mm with an inner diameter of about 0.033 mm and is operatedat a fluid pressure of about 0.5 psi to about 1.5 psi (about 0.035 toabout 0.105 Kg force per square cm). Each of the dye nozzles 56 ispreferably connected via tubing 60 to the common pressurized dye 20 feedsource 54 (FIG. 3) by a dye inlet 62. Thus, each of the dye nozzles 56preferably transmits a dye stream 58 of substantially the samecharacter. In order to apply discrete short color segments to theindividual yarns 12, the illustrated dye stream application module 52includes a multiplicity of gas nozzles 64 having an outer diameter ofabout 0.083 mm with an inner diameter of about 0.049 connected to apressurized gas source 66 such as instrument quality air or nitrogen ata pressure of about 12 to about 15 psi (about 0.84 to about 1.05 Kgforce per square cm) via an air line 68. Gas flow through the nozzles 64is cycled on and off in a predetermined programmed manner by fast actingvalves 70 such as valve model LFAX0512000BA which is believed to beavailable from the Lee Company having a place of business in Westbrooke,Conn. USA. The valves 70 are preferably controlled by the operatingcomputer 33. In this regard, it is contemplated that the valves 70 maybe operated either in unison or individually via control signals carriedby transmission lines 72 linked to the operating computer 33 or othercontrol device such as a programmable logic controller or the like asmay be known to those of skill in the art.

[0029] In operation, the dye stream application module 52 is preferablyenclosed within a box-like frame structure 74. A latch structure 76 maybe used to remove a face panel to gain access to the valves 70 and othercomponents within the interior of the dye stream application module 52to facilitate maintenance and adjustment as may be desired.

[0030] As best illustrated in FIG. 5, upon opening of one or more of thevalves 70, a gas impingement jet is projected through the gas nozzles 64and into contact with the dye stream 58. As shown, the jet exiting thegas nozzles 64 intercepts the dye stream 58 at a position above theplane of the yarn sheet 20 thereby deflecting the dye stream 58 awayfrom its normal path on one side of an opposing yarn 12 as shown in FIG.4 and into an alternative deflected path adjacent the opposite side ofthe same yarn 12 as illustrated in FIG. 5. During this transition, thedye stream 58 is caused to sweep across the adjacent yarn 12 in thedirection indicated by the arrows in FIG. 5 until the lower portion ofthe dye stream 58 is in general alignment with the gas nozzles 64causing the deflection. As will be appreciated, during the deflectionprocess, the dye stream 58 applies a short band of color across theyarns 12. Likewise, when the flow of impinging gas is terminated fromthe gas nozzles 64, the dye stream 58 resumes its normal flow path asshown in FIG. 4. During this recovery, another short segment of dye isagain applied across the yarns 12. The intermittent activation anddeactivation of the valves 70 provides for short disperse spots of colorwith lengths as short as about 1 mm or less along the length of theyarns 12. This process may be repeated at each of the dye applicationstations 50 along the travel path of the yarn sheet 20 so as to applyvirtually any arrangement of colors along the length of the yarns 12.The result is a yarn 12 having an arrangement of color bands disposed ina predetermined arrangement wherein the color bands may have controlledshort lengths even if the yarn 12 has a low denier rating.

[0031] By way of example only, and not limitation, an arrangement ofcolors as may be applied along a yarn 12 within the dye applicator 22incorporating five dye stream application stations 50 is shown in FIG.6. As illustrated, the yarn 12 includes six substantially discrete colorsegments 80, 81, 82, 83, 84 and 85 corresponding to a base shade appliedat the dye application roll 40 and five colors applied at the dye streamapplication stations 50. Of course, any other number of color segmentsmay be applied by increasing or decreasing the number of dye applicationstations.

[0032] As indicated, the length of the color segments 80-85 may behighly variable depending upon the desired pattern. However, accordingto the potentially preferred practice, the lengths of a substantialportion of the color segments 80-85 are preferably less than about 2inches (50.8 mm) and will more preferably be less than about 0.5 inches(12.7 mm) and are most preferably about 1 mm to about 10 mm. It isbelieved that such short color segments may be beneficial in thedevelopment of a substantially diverse seemingly random colorarrangement across the surface of a textile material incorporating lowdenier yarns. In order to avoid streaks or patterning, it iscontemplated that preferably a substantial portion and more preferablyat least about 50% or more of the color segments 80-85 within the yarn12 making up the formed textile are of lengths less than about 2 inches(50.8 mm). At least some percentage of the color segments (up to 100%)may be of even shorter length in the range of 1 mm to about 12.5 mm.

[0033] Surprisingly, it is possible to produce multicolored yarns 12spanning a large range of constructions and linear densities. Inparticular, it has been found that yarns 12 incorporating thepotentially desirable short color segments may have a broad range oflinear densities making them useful in a broad range of applications. Byway of example, the yarn 12 may have a linear density of about 500denier or less and more preferably has a linear density of about 70denier to about 250 denier and most preferably has a linear density ofabout 150 denier. One potentially preferred yarn 12 is a single ply 150denier continuous filament polyester yarn having 34 filaments per yarn.Another exemplary yarn is a single ply 70 denier continuous filamentyarn having 36 filaments per yarn. Still another exemplary yarn is a 2ply 250 denier continuous filament polyester yarn having 100 filamentsper yarn. It is also contemplated that spun yarn constructions of suchlow deniers as well as yarns of substantially greater denier and/or ofdifferent materials such as nylon may be utilized if desired.

[0034] It is to be appreciated that while the color segments extendingalong the yarn 12 may be extremely short, it is also contemplated thatmuch longer color segments may also be applied. Such extended colorsegments which may be virtually infinite in length may be formed byrapidly cycling the valves 70 on and off so as to cause the dye streamto undergo sweeping deflection and recovery at a rate such that there isno visible gap between segments of applied dye. This capability permitsone to impart dye segments of virtually any length as may be desired.The ability to impart extended lengths of dye to the yarn 12 is usefulin both space-dyeing as well as in solid shade dyeing of a wide array ofyarn types including yarns without good wicking characteristics such asuntextured hard yarns or so called “partially oriented yarns” which haveheretofore been difficult to dye with uniformity in traditional packagedye processes and have relied upon solution dyeing the polymer fromwhich such yarns are formed. Thus, the techniques as described hereinmay be used to impart both discrete or substantially extended lengths ofcolor to such yarns as may be desired. Of course virtually any otheryarn type may also be dyed as well.

[0035] It is contemplated that aside from imparting both short and longcolor segments to the yarn 12, the dye applicator 22 may be utilized tocarry out selected color blending on the yarns 12. By way of exampleonly and not limitation, it is contemplated that such color blending maybe carried out by using one or more of the later encountered dye streamapplication stations 50 to apply dye over dye segments previouslyapplied by one or more dye stream application stations 50 locatedupstream. As will be appreciated, upon the occurrence of such blending acolored segment is produced representing the dye mixture at the locationof blending. Of course, since the number of dye stream applicationstations 50 is in no way limited, virtually any number of overdyingoperations may take place to produce an infinite number of coloroptions. The length of the overdyed color segments so produced may be asshort as about 1 mm to an infinite length corresponding to the entirelength of the yarn 12.

[0036] It is contemplated that the yarns 12 may be formed into a numberof fabric constructions including relatively light weight constructionsuseful in a number of applications. According to one potentiallypreferred practice, short color segments 80-85 provide seeminglyrandomly disperse spots of color across an outer face surface of theformed textile material. Such random coloration supplies a surprisinglyattractive appearance while the relatively low linear density of theyarns 12 permits the formation of relatively light weight materials.

[0037] As illustrated in FIG. 7, according to one embodiment the yarn 12may be formed into a woven textile fabric 88 wherein yarn 12incorporating short color segments 80-85 runs in a weft direction ininterwoven relation to a multiplicity of warp yarns 90. Of course, it isalso contemplated that the yarn 12 incorporating the color segments80-85 may also run in the warp direction if desired. The woven textilefabric 88 may be formed by weaving practices as will be well known tothose of skill in the art including plain weaving, dobbie weaving andjacquard weaving, although dobbie and jacquard weaving may potentiallybe preferred.

[0038] According to one potentially preferred practice, the yarn 12incorporating the short color segments 80-85 makes up not more thanabout 40% by weight of the woven textile fabric 88 and preferably makeup about 5%-35% by weight. In one exemplary construction, the woventextile fabric has a weave density of about 35 to about 130 warp endsper inch (preferably about 40 to about 125 warp ends per inch) and about25 to about 60 weft yarns per inch (preferably about 30 to about 54 weftyarns per inch) wherein all yarns have a linear density of about 70 toabout 150 denier. The resulting woven textile fabric 88 preferably has amass per unit area in the range of about 9 to about 20 ounces per squareyard (about 305 to about 679 grams per square meter) therebyfacilitating use in a number of applications such as automotive seatcoverings and the like wherein substantial weight may be undesirable.The warp yarns 90 may be of either the same or different physicalconstruction from the yarns 12 incorporating the color segments 80-85.

[0039] As previously indicated, the short color segments 80-85 along thelength of the yarn 12 provide short discontinuous points of color acrossthe surface of the woven textile fabric 88. Thus, in the illustrativeconstruction illustrated in FIG. 7, the segment of color 82 is visibleacross a short distance “a” spanning two knuckles across the fabricsurface while the adjacent color segment 83 is visible across a distance“b” spanning a single knuckle. Of course the scale of such distances isgreatly enhanced for illustrative purposes and in practice the distances“a” and “b” will appear as substantially discrete points of color withinthe overall structure of the woven textile fabric 88. These discretepoints of color have been found not to form coordinated visible patternssuch as chevrons or the like across the surface of the fabric 88 whilenonetheless providing potentially pleasing coloration. Moreover, it hasbeen surprisingly found that the percentage of yarn 12 incorporating thecolor segments 80-85 which is necessary to impart desired aestheticcoloration may be extremely low. As indicated, it is contemplated that awoven textile fabric 88 preferably incorporates no more than about 40%by weight of such colored yarn 12 and preferably incorporates about 5 toabout 35% by weight of such colored yarn 12. It is believed that theshort color segments 80-85 facilitate the use of such low percentagesdue to the fact that the disperse discrete spots of color provide a userwith a visual perception of an enhanced level of coloration even at suchlow percentages.

[0040] Aside from woven constructions, it is also contemplated that theyarn 12 including the discrete color segments 80-85 may be utilized inknit fabric constructions. In particular, it is contemplated that theyarn 12 may make up a portion of the yarn forming the face of such aknit fabric. By way of example only and not limitation, a needle-pointdiagram illustrating the construction of a double needle bar plush knitfabric is illustrated in FIG. 8. The illustrated pattern is used to forma 6 bar double needle bar warp knit fabric which may be slit to yield ashort fiber length pile surface. In such a construction a ground yarn 90is disposed at Bar 1 and Bar 6, a tie yarn 91 is disposed at Bar 2 andBar 5 and cooperating face yarns 92 are disposed at Bar 3 and Bar 4. Theyarn 12 including the discrete color segments 80-85 makes up at least aportion of the face yarns at Bar 3 and Bar 4 so as to impart facecoloration. In one potentially preferred construction the ground yarn 90and the tie yarn 91 are single ply 70 denier continuous filamentpolyester yarn with about 36 filaments per yarn although virtually anyother suitable yarn as may be known to those of skill in the art mayalso be utilized as the ground yarn 90 and tie yarn 91. The face yarnsare preferably single ply 150 denier continuous filament polyesterhaving 34 filaments per yarn although virtually any other suitable yarnas may be known to those of skill in the art may also be utilized at theface. By way of example only, one alternative face yarn 92 which may beutilized at the face is a 250 denier continuous filament polyesterhaving 100 filaments per yarn.

[0041] By way of example only, it is contemplated that a construction asillustrated in FIG. 8 may be formed on well known knitting equipmentsuch as 32 gauge or 44 gauge double needle bar machines. As with thewoven textile woven fabric 88, the use of yarns 12 incorporating shortcolor lengths provides an arrangement of substantially discretediscontinuous points of color across the finished fabric. While thespace dyed yarns 12 incorporating the short color segments as describedabove may make up any percentage of the final fabric, such yarns arepreferably located preferentially at the face and make up not more thanabout 40% by weight of the final fabric and most preferably make up inthe range of about 5% to about 35% by weight of the fabric.

[0042] The utilization of the low denier yarns provides the ability toform relatively light weight knit fabric constructions. By way ofexample, in a 32 gauge construction the fabrics formed using the 150denier face yarn with 70 denier ground yarns and tie yarns typically hasabout 20 to about 26 courses per inch and about 17 wales per inch with afabric weight of about 9 to about 12 ounces per square yard (about 305to about 407 grams per square meter). In a 44 gauge construction, thedouble needle bar knit fabrics typically have about 25 to about 30courses per inch with about 25 wales per inch and a fabric weight ofabout 9 to 16 ounces per square yard (about 305 to about 542.5 grams persquare meter).

[0043] It is to be appreciated that the yarn 12 incorporating the shortcolor segments as described above may also be formed into a number ofother knit constructions. By way of example only, it is contemplatedthat a relatively low denier yarn such as a single ply 70 denier or 150denier continuous filament polyester yarn may be knitted on a knittingmachine in a two to four bar construction. The surface of the fabric maythereafter be napped by a wire wheel, sander or other abrasive elementas will be known to those of skill in the art to raise a textured pilesurface thereby forming a so-called “nap knit” construction. The yarns12 incorporating the color segments 80-85 preferably make up only about5 to about 35 weight percent of the fabric in this construction.

[0044] One exemplary two bar warp knit construction pattern suitable forthe formation of a nap knit fabric is illustrated in FIG. 9. In such aconstruction the Bar 1 yarn 93 and Bar 2 yarn 94 are each preferably asingle ply continuous filament polyester yarn having a linear density inthe range of about 70 denier to about 500 denier. Lower denier ratingsin the range of about 70 denier to about 250 denier may be preferred forsome applications. One exemplary nap knit construction utilizing a 150denier polyester continuous filament yarn with 34 filaments per yarnyields a knit construction having about 33 courses per inch and about 25wales per inch with a fabric weight in the range of about 9 to 10 ouncesper square yard (about 305 to about 339 grams per square meter). Lowerdenier yarns such as the single ply 70 denier continuous filamentpolyester yarn with about 36 filaments per yarn may be utilized in evenfiner structures such as may be formed on 56 gauge knitting machines. Ofcourse, virtually any other fabric construction such as circular knitsor the like may also be formed if desired.

[0045] It is to be understood that while the present invention has beenillustrated and described in relation to certain potentially preferredembodiments, constructions, and procedures, that such embodiments,constructions and procedures are illustrative only and that the presentinvention is in no event to be limited thereto. Rather, it iscontemplated that modifications and variations embodying the principlesof the invention will no doubt occur to those of skill in the art. It istherefore contemplated and intended that the present invention shallextend to all such modifications and variations as may incorporate thebroad aspects of the invention within the full spirit of scope thereof.

That which is claimed is:
 1. A yarn comprising: a plurality of discretecolor segments arranged in a predefined spaced relation along said yarn,wherein at least a portion of said color segments are of finite lengthless than about 2 inches and wherein said yarn has a linear density ofnot greater than about 500 denier.
 2. The yarn as recited in claim 1,wherein said yarn is a single ply yarn.
 3. The yarn as recited in claim2, wherein said yarn has a linear density in the range of about 70 toabout 250 denier.
 4. The yarn as recited in claim 1, wherein said yarnis a single ply continuous filament yarn.
 5. The yarn as recited inclaim 4, wherein said yarn has a linear density in the range of about 70to about 250 denier.
 6. The yarn as recited in claim 1, wherein saidyarn is a multi-filament yarn.
 7. The yarn as recited in claim 6,wherein said yarn has a linear density of about 70 to about 150 denier.8. The yarn as recited in claim 1, wherein said yarn is an untexturedyarn.
 9. The yarn as recited in claim 1, wherein said yarn is apartially oriented yarn.
 10. The yarn as recited in claim 1, wherein atleast a portion of said color segments comprise a first topicallyapplied dye segment and at least a second topically applied dye segmentdisposed over said first topically applied dye segment.
 11. A yarncomprising: a plurality of discrete color segments arranged in apredefined spaced relation along said yarn, wherein at least a portionof said color segments are of finite length less than about 0.5 inchesand wherein said yarn has a linear density of not greater than about 500denier.
 12. A textile material comprising: a plurality of multi-coloredyarns wherein said multi-colored yarns have a linear density of notgreater than about 500 denier and include a plurality of discrete colorsegments of finite length arranged in predefined spaced relation alongsaid mult-colored yarns and wherein at least a portion of said discretecolor segments have a length less than about 2 inches.
 13. The textilematerial as recited in claim 12, wherein the textile material is a wovenfabric.
 14. The textile material as recited in claim 13, wherein thewoven fabric has a mass per unit area in the range of about 9 to about20 ounces per square yard.
 15. The textile material as recited in claim13, wherein the woven fabric is selected from the group consisting of:dobbie woven fabric and jacquard woven fabric.
 16. The textile materialas recited in claim 15, wherein at least a portion of said multi-coloredyarns are single ply yarns.
 17. The textile material as recited in claim16, wherein said multicolored yarns have a linear density in the rangeof about 70 to about 250 denier.
 18. The textile material as recited inclaim 12, wherein the textile material is a woven fabric comprising aplurality of multi-filament warp yarns having a linear density of about70 to about 150 denier disposed within the woven fabric at a weavedensity of about 35 to about 130 warp yarns per inch, and wherein themulti-filament warp yarns are interwoven with a plurality ofmulti-filament weft yarns having a linear density of about 70 to about150 denier disposed within the woven fabric at a weave density of about25 to about 60 weft yarns per inch.
 19. The textile material as recitedin claim 18, wherein the multi-filament warp yarns are disposed withinthe woven fabric at a weave density of about 40 to about 125 warp yarnsper inch.
 20. The textile material as recited in claim 18, wherein themulti-filament weft yarns are disposed within the woven fabric at aweave density of about 30 to about 54 weft yarns per inch
 21. Thetextile material as recited in claim 12, wherein the textile material isa knit fabric.
 22. The textile material as recited in claim 21, whereinthe knit fabric has a mass per unit area in the range of about 9 toabout 16 ounces per square yard.
 23. The textile material as recited inclaim 21, wherein said multicolored yarns are single ply continuousfilament yarns.
 24. The textile material as recited in claim 23, whereinsaid multicolored yarns have a linear density in the range of about 70to about 250 denier.
 25. The textile material as recited in claim 12,wherein the textile material is a nap knit fabric comprising a pluralityof multi-filament yarns having a linear density of about 70 to about 150denier.
 26. The textile material as recited in claim 25, wherein the napknit fabric has about 33 courses per inch and about 25 wales per inch.27. The textile material as recited in claim 12, wherein the textilematerial is a double needle bar knit fabric and wherein saidmulti-colored yarns are multi-filament yarns having a linear density ofabout 70 to about 150 denier.
 28. The textile material as recited inclaim 27, wherein said double needle bar knit fabric is about a 32 gaugeconstruction having a fabric weight of about 9 to about 12 ounces persquare yard.
 29. The textile material as recited in claim 27, whereinsaid double needle bar knit fabric is about a 44 gauge constructionhaving a fabric weight of about 9 to about 16 ounces per square yard.30. The textile material as recited in claim 12, wherein at least aportion of said discrete color segments have a length less than about0.5 inches.
 31. A textile material comprising: a plurality ofmulti-filament polyester yarns forming an outer face surface, wherein atleast a portion of said yarns comprise multi-colored yarns including aplurality of discrete color segments of finite length less than 2 incheslong arranged in predefined spaced relation along said multi-coloredyarns such that portions of said discrete color segments formdiscontinuous spots of color at discrete visible locations across theouter face surface, said multi-colored yarns making up not more thanabout 5% to about 40% by weight of the textile material and having alinear density in the range of about 70 to about 250 denier.
 32. A spacedyed yarn comprising a plurality of discrete color segments arranged ina predefined spaced relation along said yarn wherein said yarn has alinear density less than 500 denier and wherein at least a majority ofsaid color segments have lengths in the range of less than 2 inches. 33.An apparatus for applying dye to a yarn, the apparatus comprising: atleast one dye nozzle adapted to deliver a coordinated stream of dyealong a normal stream path adjacent to said yarn; and an intermittentlyactivatable gas nozzle projecting towards said stream of dye such thatupon activation of said gas nozzle, a stream of gas impinges said streamof dye thereby diverting said stream of dye across said yarn whereby afirst band of color is applied across said yarn and such that upondeactivation of said gas nozzle, the stream of dye passes back acrosssaid yarn and resumes travel along said normal stream path adjacent tosaid yarn whereby a second band of color is applied across said yarn.34. A process for applying dye to a yarn, the process comprising:conveying said yarn to at least a first dye application stationdelivering a coordinated stream of dye from said dye station in a normalstream path adjacent to said yarn; and intermittently activating anddeactivating a gas nozzle projecting towards said stream of dye suchthat upon activation of said gas nozzle, a stream of gas impinges saidstream of dye thereby diverting said stream of dye across said yarnwhereby dye impacts and colors said yarn and such that upon deactivationof said gas nozzle, the stream of dye passes back across said yarnwhereby dye impacts and colors said yarn.
 35. The process as recited inclaim 34, wherein the gas nozzle is repeatedly activated and deactivatedover a prolonged period and wherein the period between activation anddeactivation is sufficiently short such that a substantiallyuninterrupted dyed segment is produced along the yarn.
 36. The processas recited in claim 34, wherein a period of time elapses betweenactivation and deactivation of the gas nozzle such that that a patternof separate dye segments is produced along the yarn.
 37. The process asrecited in claim 34 further comprising delivering the yarn to a seconddye application station downstream of said first dye applicationstation, whereat a second coordinated stream of dye is delivered along anormal stream path adjacent to said yarn, said second dye applicationstation including an intermittently activatable gas nozzle projectingtowards said second coordinated stream of dye such that upon activationof said gas nozzle, a stream of gas impinges said second coordinatedstream of dye thereby diverting said second coordinated stream of dyeacross said yarn whereby dye from the second dye application stationimpacts and colors said yarn and such that upon deactivation of said gasnozzle, the second coordinated stream of dye passes back across saidyarn whereby dye from the second dye application station impacts andcolors said yarn.
 38. The process as recited in claim 37, wherein atleast a portion of the dye from the second dye application stationimpacts and colors said yarn at locations along said yarn previouslycolored by dye from said first dye application station such that dyefrom said first dye application station and from said second dyeapplication station is intermixed at said locations along said yarnwhereby mixed coloration is achieved.